TECHNICAL TYPE 115 5.

TORQUES - continued Thread Nm

DATA R 14, R 16, R 20 5.3 Chassis:
Valve to reach frame M8 x 20 12
1. PRESSURE SETTINGS Bar Bar All pipe fittings M10 10
184 mast 187 mast 5.4 Electrical System:
1.1 Pressure relief valve - R14 250 250 Heavy cables to motor terminals M8 16
- R16 250 250 Power module heatsink to chassis M8x50/M8x55 25-35
- R20 250 Power module connections M5 M5 2-3
2. SETTINGS Nm mm Power module connections M8 M8 8-10
2.1 Parking brake gap 0.3 - 0.6 Heavy cables to motor terminals M5 M5 2-3
2.2 Parking brake shoe clearance 0.37 Heavy cables to motor terminals M8 M8 16
2.3 Reach sensor clearance 3.5 ± 0.5 Contactor terminations M8 M8 8-9.5
2.4 Hydraulic motor speed sensor clearance 2 ± 0.2 Isolator terminations M8 M8 12
2.5 Lift stop sensor clearance 3.5 ± 0.5 Isolator fixings M5 M5 3
2.6 Battery lock sensor clearance 3.5 ± 0.5 Isolator terminations M8 M8 8.5-10
2.7 LHI reference sensor clearance 2 ± 0.2 Current sensor M5 M5 2-3
Fuse assy M10 brass nuts M10 19.6
3. WEAR LIMITS mm mm 5.5 Hydraulic System:
Lift pump to motor (BOSCH) M10 x 100 55-58
115 804 3501.0906

3.1 Traction motor new/minimum brush length 40 17 Hose assemblies

3.2 Traction motor new/minimum commutator diameter 106 100 Emergency lower valve M12 10-13
3.3 Hydraulic motor new/minimum brush length 40 17 Lift cylinder and hydraulic pump M22 45-50
3.4 Hydraulic motor new/minimum commutator diameter 82 78 Hydraulic tank 70-80
3.5 Minimum load wheel brake lining thickness 2 Bottom of lift cylinder M36 140
3.6 Minimum parking brake shoe lining thickness 1.5 Reach cylinders M18 27-32
Additional hydraulics 40
4. FILLING QUANTITIES litres Type * Hydraulic valve fittings
Emergency lower valve M10 16-18
4.1 Gearbox 3.8 Gear oil Lift cylinder and hydraulic pump M22 60
4.2 Brake fluid (reservoir only) 0.2 Brake fluid Hydraulic tank M27 100
4.3 Hydraulic oil - 184/187 (tank only) 20.5/26.5 Hydraulic oil Reach cylinders M16 39-45
* See recommended lubricants Additional hydraulics M14 33-38
Primary to secondary cylinder pipe assy M36 140
5. TORQUES Thread Nm Secondary & primary lift cylinder bleed screws M6 x 6 10
5.6 Mast:
5.1 Drive - Motors: Mast to reach carriage-bottom fixing M20 x 80 600
Pinion gear to traction motor - slotted ring nut M20 55 Mast to reach carriage-pivot fixing M12 x 25 90
5.2 Drive - Gearboxes: Reach leg stop screws M12 x 30 50
Loadwheel locknut to stub axle (R14/R16)/(R20) M40/M45 Chain anchor prevailing torque nut with half nut M20 100
Tighten to 50 Nm, slacken off, re-tighten to 12Nm (R14/16) Free lift slowdown screw (186/187 only) M12 x 30 50
or 20Nm (R20) and turn clockwise to nearest tab on washer Switch to truck fixing screws M4 x 30 1.5
Drive wheel nut to gearbox M14 195
Lever fixing screw (Adjusted to suit application) 0.5
Drive unit to chassis - Durlock screw M20 x 55 700
Top actuator fixing screws (Not normally removed) 0.5
Cable gland to switch M20 1-2
6. RECOMMENDED LUBRICANTS 9. INSPECTION AND MAINTENANCE SCHEDULE

Hydraulic oil Inspection and maintenance as required

STANDARD - Clean the truck
Hydraulic oil grade HLP to DIN 51524 part 2. Viscosity ISO VG 46. - Lubricate the lift chains and mast channels
Cloud point lower than -10°C when tested to IP 216.82 - Adjust the lift chains
COLD STORE (STAY IN) and (IN - OUT) - Check the condition of the wheels and tyres
Anti wear hydraulic oil. Grade ISO VG 22-32. Viscosity index > 300 - Renew the motor brushes
e.g. Shell Tellus Arctic 32 - Renew the hydraulic hoses
- Check the drive wheel nuts
Multipurpose grease - Replace the battery trolley slides
STANDARD - Check and adjust the parking brake
Lithium-based grease to DIN51825, KP2K-20
COLD STORE 1000 Hour inspection and maintenance (250 Hour cold store)
Low temperature clay based grease - Check the parking brake, adjust if required
- Check the hydraulic hoses and pipes for damage
Gear oil - Check the mast and lift chains for condition and security
Use only oil of classification SHC, - Lubricate the mast, mast rollers, lift chains and chain pulleys
- Lubricate mast hose pulley assemblies (cold store version only)
Steering drive gears - Lubricate the reach channels and rollers
Multi purpose grease containing 5% Molybdenum Disulphide - Check and lubricate the battery trolley slides and associated mechanism
- Check the condition and security of motor and battery connectors and cables
General purpose oil - Check the hydraulic oil level
Engine Oil SAE 20W/50 - Lubricate the fork carriage and sideshift slider pad
- Check condition of side guide rollers (option)
Chain Spray - Lubricate cold store cab hinges and door lock (option)
STANDARD
Linde chain spray 2000 Hour inspection and maintenance (1000 Hour cold store)
COLD STORE - Visual check of motor brushes (Every 1000 hours thereafter)
Linde cold store chain spray - Check the brake fluid level
- Check the brake band and load wheel shoes for wear and adjustment
Brake fluid - Renew the hydraulic tank breather filter
Original ATE brake fluid to DOT3, type “S”, classification to FMVSS 116 or SAE J - Check the reach frame rollers, adjust if necessary
1703 issue 1980 and ISO 4925.
5000 Hour inspection and maintenance (2500 Hour cold store)
- Check condition of brake pipes
7. CHECKS AND SERVICING AFTER THE FIRST 50 HOURS OF SERVICE - Grease the load wheel bearings
- Change the hydraulic fluid
- Check all controls and their operation. - Renew the hydraulic suction line filter
- Check the brake operation.
- Tighten the wheel nuts (at least every 100 hours). 10000 Hour inspection and maintenance (or 5 years, whichever is earlier)
- Check the tyres for damage and foreign objects. 5000 Hour cold store (or 30 months, whichever is earlier)
- Renew the hydraulic suction line filter. - Change the brake fluid
- Lubricate tilt and sideshift slider pad.
- Mast and lift chain: lubricate with chain spray.
NOTES
8. DAILY CHECKS Always disconnect the battery plug in the event of a malfunction, or when carrying
out service routines.
- Battery charge Before working on the electrical control system, ensure that the steering capacitor
- All controls and their operation is fully discharged.
- Interlock switches Do not place tool on the battery - risk of short circuit
Follow the manufacturer's safety and disposal instructions when using lubricants
and cleaning compounds.
Dispose of used parts, filters etc., in an environmentally friendly manner.